Press hall laid out 60/40 for Duplex systems (special pressings first)

User (October 2026): "the factory should have more space for duplex
setups than classic, we will mainly focus on special prints and not mono
colours plan it to be 60/40 duplex classic".

- Press hall (~870 m2) planned 60/40 by floor: four Duplex bays along the
  visitor corridor and six Classic positions in the second row (440 + 300
  = ~740 m2 at 110 / 50 m2), the rest open for mould carts and staging;
  the launch plant fills one of each, growth adds Duplex systems first.
  Replaces "room for ten more Classics".
- Full hall: 8 semi-automatic presses + 6 Classics, 57/43 by press count,
  ~1,250 to 1,410 records/h gross, ~3.6 to 4.7M a year on the scale.md
  basis (was 4.7 to 5.8M for 2 Duplex + 11 Classics); ~2.1 to 2.5 t/h
  steam and up to ~1.8 MW cooling, still a utility phase of its own.
  By hourly output the six automatic Classics still press more than the
  eight semi-automatic presses (estimate).
- pressing-line.md, scale.md (capacity table, utilities), site-candidates
  .md, crane-workshop-tours.md, roadmap.md, README (the FreeCAD Payap
  model still draws the earlier layout; noted, not redrawn).
- Calculator: preset "Full hall 60/40 (4 D + 6 C)", fleet ladder Duplex
  first (1+1, 2+1, 3+2, 4+3, 4+6) plus the same floor Classic-led (2+11)
  and Duplex-only (7+0) for comparison; plant view reserves 4 Duplex
  bays and 6 Classic positions.
- Business plan draft 0.2 rebuilt (capacity table row, plot fit, layout).

Checks: renderer 720 checks pass (node budget 2,700 for the Duplex-heavy
stress preset, 60 fps), calculator regression 0 fails, level selector and
page checks clean at 390 / 1024 / 1440 px dark and light; PDF 47 pages
with a filled table of contents.

README.md

@@ -149,7 +149,9 @@ The detail lives in dedicated documents:
   BIM model in FreeCAD 26.3 (`docs/cnx_vinyl_parametric_payap.FCStd`,
   [isometric](docs/cnx_vinyl_parametric_payap-iso.png)) of the whole plant
   on a square placeholder plot of Payap land: a 128 x 25 m production-only
-  factory with the five-press fleet, room for ten more Classics, one
+  factory with the five-press fleet, room for ten more Classics (drawn
+  before the October 2026 decision to lay the hall out 60/40 for Duplex
+  systems: four Duplex bays and six Classic positions), one
   shared hydraulic and air plant, a colour store with outdoor silos and a
   two-storey finishing and print block
   ([plans](docs/cnx_vinyl_parametric_payap-block.png)), a separate

docs/business-plan/build/content_a.py

@@ -548,8 +548,8 @@ def blocks():
              "~0.71 to 0.97 million records"],
             ["Growth option: second Duplex", "4 semi-automatic + 1 Classic, 2 shifts; room reserved, not in "
                                              "the investment", "~1.0 to 1.5 million records"],
-            ["Expansion option", "The five-press fleet plus up to ten more Classics; a utility phase of its "
+            ["Full hall (option)", "4 Duplex systems + 6 Classics, the press hall laid out 60/40 for Duplex "
-                                 "own", "~4.7 to 5.8 million records (estimate)"],
+                                   "(special pressings first); a utility phase of its own", "~3.6 to 4.7 million records (estimate)"],
         ], widths_mm=[40, 80, 50],
            caption="Basis: semi-automatic 60 to 80 records/h assumed; Classic ~128/h (vendor flyer); 16 h/day, "
                    "300 days/yr, 60 to 70% overall equipment effectiveness. The launch plant is 248 to 288 "

docs/business-plan/build/content_b.py

@@ -487,7 +487,7 @@ def blocks():
             "**Flooding:** Payap describes the land as low-lying when bought; check the plot against the "
             "2024 flood extents.",
             "**Plot fit:** the building, the detached utility yard and a second building need 6 to 8 rai; "
-            "the Payap scenario model draws a 150 m square (14.1 rai) with room for ten more Classics.",
+            "the Payap scenario model draws a 150 m square (14.1 rai) with room for the full press hall.",
             "**Galvanics on a campus:** the lessor's written consent; zero discharge becomes a lease "
             "condition, not only a commitment.",
         ]),
@@ -628,7 +628,8 @@ def blocks():
           "It is where finished goods move to free production floor, where pressing capacity can double, "
           "or where a CD replication line would go if that option is chosen (section 4.9). Where the "
           "second Duplex system stands on the Mueang Chi footprint is not drawn yet; the Payap scenario "
-          "model draws the whole five-press fleet with room for ten more Classics."),
+          "model draws the five-press fleet; its press hall is now planned 60/40 for Duplex systems (four "
+          "Duplex bays and six Classic positions), because the plant focuses on special pressings."),
         H3("What the construction RFQ asks"),
         P("The budget-level construction RFQ, with quantities from the parametric model, asks contractors "
           "for: the shell rate per m² at the insulated-panel specification (not a bare shed); heavy-duty "

docs/crane-workshop-tours.md

@@ -321,8 +321,8 @@ into a separate office building, so only production sits under the
 crane. The tour then starts in the office building, at the cutting-room
 window and the listening room, and crosses a covered link into a 98 m
 corridor. That is longer than the 45 to 55 m assumed below, because the
-press hall keeps room for ten more Classics and a colour store sits
+press hall keeps room for four Duplex systems and six Classics and a
-before it. In that model the crane runway ends at the press hall:
+colour store sits before it. In that model the crane runway ends at the press hall:
 finishing and packaging sit beyond it in a two-storey block with the
 print room and stocks upstairs, which the crane cannot serve, so loads
 there move by forklift and goods lift. The model also draws the

docs/equipment/pressing-line.md

@@ -96,14 +96,25 @@ automated candidate). What it means:
   between machines. The EX 35 and trimmer footprints are not published,
   so those are estimates. The [Payap scenario model](../site-candidates.md#payap-scenario-model-october-2026) draws
   both systems this way.
-- **Room to grow: possibly ten more Classics.** The plant may add up to
+- **Room to grow: a hall laid out 60/40 for Duplex systems (October
-  ten more Newbilt Classics at some point. This is an option, not part of
+  2026).** The plant will mainly press special editions (splatter, colour
-  the plan or the investment: the layout keeps floor for it (ten Classic
+  effects, small runs), not mono colours, so the press hall keeps more
-  positions in the Payap scenario model), and the central hydraulic and
+  floor for Duplex systems than for Classics: 60/40 by floor, four Duplex
+  bays (the launch system and three more) and six Classic positions (the
+  launch Classic and five more). At the calculator's floor figures (110 m²
+  per Duplex bay, 50 m² per Classic) that is 440 + 300 = ~740 m² of the
+  ~870 m² hall; the rest stays open for mould carts and staging. Growth
+  adds Duplex systems first. The full hall is eight semi-automatic presses
+  and six Classics, 57/43 by press count; by hourly output the six
+  automatic Classics still press more (~770 against 480 to 640 records an
+  hour, estimate). This is an option, not part of the plan or the
+  investment: the layout keeps the floor, and the central hydraulic and
   air plant should be sized or extendable for it. At Newbilt's per-press
-  figures, fifteen presses would draw ~2.3 to 2.7 t/h of steam and up to
+  figures, the fourteen presses would draw ~2.1 to 2.5 t/h of steam and up
-  ~1.9 MW of cooling, so boiler, chiller and grid connection would be a
+  to ~1.8 MW of cooling, so boiler, chiller and grid connection would be a
-  phase of their own ([scale](../scale.md)).
+  phase of their own ([scale](../scale.md)). The Payap scenario model in
+  FreeCAD still draws the earlier layout (two Duplex bays and eleven
+  Classic positions).
 - **Capacity** at maturity stays at ~1.0 to 1.5 million records a year on
   two shifts, the range the [revenue model](../finance/revenue-model.md)
   uses: four semi-automatic presses at 60 to 80 records an hour (estimate)
@@ -132,7 +143,8 @@ automated candidate). What it means:
   flyer's Duplex main configuration runs two presses on one extruder); the
   Classic's price, weight, power, steam and cooling figures; and the
   central hydraulic supply (an option the flyer offers) for the whole
-  fleet, extendable to ten more Classics, including whether the Classic
+  fleet, extendable to the full hall (four Duplex systems, six Classics),
+  including whether the Classic
   can run from it, whether the presses hold their pressure from it over
   the ring-main lengths of the hall, the filtration and isolation each
   branch needs, and whether the Single 2.1's aggregate can be its first

docs/fleet-calculator.html

@@ -612,7 +612,7 @@ html[data-theme=light] .iso-svg .iso-glint { display: inline; }
     <button type="button" data-p="levers">Investor levers (216M)</button>
     <button type="button" data-p="lean">Lean: bought stampers, outsourced cutting</button>
     <button type="button" data-p="five">Five-press fleet (second Duplex)</button>
-    <button type="button" data-p="full">Full hall, Classic-led (2 D + 11 C)</button>
+    <button type="button" data-p="full">Full hall 60/40 (4 D + 6 C)</button>
   </div>
 </header>
 
@@ -813,9 +813,10 @@ html[data-theme=light] .iso-svg .iso-glint { display: inline; }
 
   <section class="card">
     <h2>From small to fully equipped</h2>
-    <p class="note" style="margin-top:0">Fleets from the launch plant to a full Payap press hall (about 870 m²:
+    <p class="note" style="margin-top:0">Fleets from the launch plant to a full Payap press hall (about 870 m²,
-      the two Duplex bays plus the Classic and ten more Classic positions, or the same floor
+      laid out 60/40 by floor for Duplex systems because the plant focuses on special pressings: four
-      with more Duplex systems), at the current settings and plant configuration. Click a row to load it.</p>
+      Duplex bays and six Classic positions, ~740 m²), then the same floor filled Classic-led or with
+      Duplex systems only, for comparison, at the current settings and plant configuration. Click a row to load it.</p>
     <div class="tscroll"><table id="ladT"></table></div>
   </section>
 
@@ -1238,7 +1239,9 @@ html[data-theme=light] .iso-svg .iso-glint { display: inline; }
   function X(fx) { return FX + fx; }
   function Y(fy) { return FY + fy; }
   // Press hall: 2 rows, 8 m deep. Slot lengths follow the calculator's floor
-  // figures (110 m2 per Duplex bay, 50 m2 per Classic, 870 m2 hall).
+  // figures (110 m2 per Duplex bay, 50 m2 per Classic, 870 m2 hall). Laid out 60/40 by floor
+  // for Duplex systems (special pressings first, October 2026): 4 Duplex bays + 6 Classic positions.
+  var HALL_D = 4, HALL_C = 6;
   var HALL = { cap: 870, aD: 110, aC: 50 };
   var HROWS = [{ x: X(40), y0: Y(3.6), y1: Y(11.6), len: 52 }, { x: X(47.8), y0: Y(12.4), y1: Y(20.4), len: 44.2 }];
   var LTOT = 52 + 44.2, WD = HALL.aD / HALL.cap * LTOT, WC = HALL.aC / HALL.cap * LTOT;
@@ -1279,8 +1282,8 @@ html[data-theme=light] .iso-svg .iso-glint { display: inline; }
     var D = cfg.duplex, Cn = cfg.classic, A = 0, Dh = 0, Ch = 0, i, items = [];
     while (Dh < D && A + HALL.aD <= HALL.cap + 1e-9) { Dh++; A += HALL.aD; }
     while (Ch < Cn && A + HALL.aC <= HALL.cap + 1e-9) { Ch++; A += HALL.aC; }
-    var eD = Math.max(0, 2 - Dh); while (eD > 0 && A + eD * HALL.aD > HALL.cap) eD--;
+    var eD = Math.max(0, HALL_D - Dh); while (eD > 0 && A + eD * HALL.aD > HALL.cap) eD--;
-    var eC = Math.max(0, 11 - Ch); while (eC > 0 && A + eD * HALL.aD + eC * HALL.aC > HALL.cap) eC--;
+    var eC = Math.max(0, HALL_C - Ch); while (eC > 0 && A + eD * HALL.aD + eC * HALL.aC > HALL.cap) eC--;
     for (i = 0; i < Dh; i++) items.push({ t: "D", n: i + 1 });
     for (i = 0; i < eD; i++) items.push({ t: "D", e: 1 });
     for (i = 0; i < Ch; i++) items.push({ t: "C", n: i + 1 });
@@ -1562,7 +1565,7 @@ html[data-theme=light] .iso-svg .iso-glint { display: inline; }
     sc.inf("factory", "Factory, 128 x 25 m",
       "Production floor only (Payap scenario model): workshop, galvanics, stamper prep, PVC lab, colour store, press hall, finishing block; warehouse and dispatch behind the fire wall. Monopitch roof, low eave 7.0 m, high side 11.4 m.");
     sc.inf("presshall", "Press hall, ~870 m2",
-      al.Dh + " Duplex system" + (al.Dh === 1 ? "" : "s") + " and " + al.Ch + " Classic" + (al.Ch === 1 ? "" : "s") + " in the hall; laid out for 2 Duplex bays + 11 Classic positions (Payap scenario model)" +
+      al.Dh + " Duplex system" + (al.Dh === 1 ? "" : "s") + " and " + al.Ch + " Classic" + (al.Ch === 1 ? "" : "s") + " in the hall; laid out 60/40 by floor for special pressings: 4 Duplex bays and 6 Classic positions, ~740 m2 (pressing-line.md)" +
       (al.p2need ? "; " + (al.ovD + al.ovC) + " more in the phase 2 building" : ""));
     sc.inf("galvanics", cfg.galvanics ? "Galvanics clean room (Pheenix Alpha line)" : "Galvanics room: stampers bought in",
       cfg.galvanics ? "PASU, PPPU, PDPU, PMPB; one PDPU covers full-capacity demand, a second is redundancy (galvanics.md). Room-in-room under the crane, open to stamper prep." :
@@ -1680,7 +1683,7 @@ html[data-theme=light] .iso-svg .iso-glint { display: inline; }
         fl.flat(pts, z + 0.015, "iso-slot iso-empty", id);
         sc.inf(id, sl.t === "D" ? "Duplex bay (room reserved)" : "Classic position (reserved)",
           sl.t === "D" ? "Growth option: room, utility modules and ring-main tees reserved, not in the investment (pressing-line.md)" :
-            "Floor kept for up to ten more Classics (option, not in the plan)");
+            "Classic position kept for growth (option, not in the investment); the hall is laid out 60/40 for Duplex systems (pressing-line.md)");
       } else fl.flat(pts, z + 0.015, "iso-slot", sl.t === "D" ? "duplex-" + sl.n : "classic-" + sl.n);
       if (!sl.e && sl.t === "D") {
         var cx = (sl.x0 + sl.x1) / 2, cy = (sl.y0 + sl.y1) / 2;
@@ -3076,8 +3079,9 @@ function caseNow() {
   return "";
 }
 const LADDER = [
-  ["Launch plant", 1, 1], ["Second Duplex", 2, 1], ["Step 1", 2, 3], ["Step 2", 2, 5], ["Step 3", 2, 8],
+  // Duplex systems first: the hall is laid out 60/40 by floor for them (special pressings, October 2026)
-  ["Full hall, Classic-led", 2, 11], ["Full hall, mixed", 4, 7], ["Full hall, specials-led", 6, 3],
+  ["Launch plant", 1, 1], ["Second Duplex", 2, 1], ["Step 1", 3, 2], ["Step 2", 4, 3],
+  ["Full hall 60/40", 4, 6], ["Same floor, Classic-led", 2, 11], ["Same floor, Duplex only", 7, 0],
 ];
 // presets: fleet plus plant configuration; prices, case and assumptions stay as they are
 const CFG0 = Object.fromEntries(CFGK.map(k => [k, S0[k]]));
@@ -3087,7 +3091,7 @@ const PRESETS = {
   levers: { ...LAUNCH, solar: "ppa", metro: "launch", galvPrice: "oms", corridor: "later" },
   lean: { ...LAUNCH, galv: "bought", cut: "out" },
   five: { mode: "fleet", dFleet: 2, cFleet: 1, ...CFG0 },
-  full: { mode: "fleet", dFleet: 2, cFleet: 11, ...CFG0 },
+  full: { mode: "fleet", dFleet: 4, cFleet: 6, ...CFG0 },
 };
 
 let S = { ...S0 }, A = { ...A0 };

docs/roadmap.md

@@ -173,4 +173,5 @@ Since October 2026 the plant launches with everything in one capital
 round (~161M to 292M THB, target ~216M with the levers in
 [total investment](finance/total-investment.md#launch-plant-october-2026));
 the gates still come before the round is spent, and the growth options
-(second Duplex, more Classics) are funded from revenue.
+(more Duplex systems first, then Classics, in a press hall laid out 60/40
+for Duplex) are funded from revenue.

docs/scale.md

@@ -11,7 +11,7 @@ page as real quotes and the site decision land.
 |---|---|---|
 | Launch plant (decided October 2026) | 2 semi-auto (Duplex system 1: EX 50 main + EX 35 colour extruder) + 1 automated (Newbilt Classic), commissioned in sequence, 2 shifts at volume | ~0.71 to 0.97 million records/yr |
 | Growth option: second Duplex | 4 semi-auto (two Duplex systems) + 1 Classic, 2 shifts; room reserved, not in the investment | ~1.0 to 1.5 million records/yr |
-| Expansion (option) | the five-press fleet + up to 10 more Newbilt Classics, 2 shifts | ~4.7 to 5.8 million records/yr (estimate) |
+| Full hall (option) | 4 Duplex systems + 6 Classics, the hall laid out 60/40 for Duplex, 2 shifts | ~3.6 to 4.7 million records/yr (estimate) |
 
 The [press fleet calculator](fleet-calculator.html) sizes the fleet for
 any yearly output and specials share, with the people and utilities it
@@ -44,10 +44,14 @@ effectiveness of 60 to 70% applied: 368 to 448 records/hour, ~1.06 to 1.5
 million a year. The theoretical ceiling of the mature fleet at 100% uptime
 is roughly 1.8 to 2.2 million records per year. (The earlier 50/50 fleet,
 two semi-automatic presses and two Pheenix AD12s, landed in the same
-range.) The expansion row is an option the plant keeps room for, not a
+range.) The full-hall row is an option the plant keeps room for, not a
-plan: ten more Classics add ~1,280 records/hour on the same basis, and
+plan: the press hall is laid out 60/40 by floor for Duplex systems, since
-neither the [revenue model](finance/revenue-model.md) nor the investment
+the plant focuses on special pressings
-includes them.
+([pressing line](equipment/pressing-line.md)). Eight semi-automatic
+presses and six Classics give 1,250 to 1,410 records/hour gross, ~3.6 to
+4.7 million a year on the same basis, and neither the
+[revenue model](finance/revenue-model.md) nor the investment includes
+them.
 
 **The 60–70% effectiveness assumption is worth challenging, but not yet
 changing.** Newbilt publishes ≥95% yield and ≥95% uptime for the Classic
@@ -254,8 +258,9 @@ kW hydraulic oil cooler) at 305 to 540 l/min of circulating water. The
 peak rows assume all five presses cooling hard on a hot afternoon; the
 Classic counts as one HRP 12 press plus one extruder until Newbilt states
 its figures. The presses share one central hydraulic plant and one
-compressed-air plant. The optional ten more Classics would need up to ~1.9
+compressed-air plant. The optional full hall (four Duplex systems and six
-MW of cooling and ~2.3 to 2.7 t/h of steam: a utility phase of its own.
+Classics, fourteen presses) would need up to ~1.8 MW of cooling and ~2.1
+to 2.5 t/h of steam: a utility phase of its own.
 
 Tariff: PEA Schedule 3.2.2, Medium General Service on time of use at
 22 kV (the flat rate is closed to new customers): 132.93 THB/kW demand

docs/site-candidates.md

@@ -122,7 +122,8 @@ dropped. Source record with the zone's full rules and annex:
 5. **Plot fit.** Shape and size against the 60 × 25 m building, the
    detached utility yard and the phase 2 footprint (6 to 8 rai). The
    Payap scenario model below needs a 150 m square (14.1 rai) as drawn,
-   with room for ten more Classics, a colour store and a reserve.
+   with a press hall laid out 60/40 for Duplex systems, a colour store and
+   a reserve.
 6. **Galvanics on a campus.** Phase 5 electroplating needs the lessor's
    written consent; the zero-discharge design
    ([sustainability](sustainability.md)) becomes a lease condition, not
@@ -155,7 +156,7 @@ and every equipment envelope is an estimate.
 
 - **Plot**: 150 × 150 m (22,500 m², 14.1 rai), road assumed on the south
   side, 6 m setbacks (placeholder). That is about twice the 6 to 8 rai of
-  [scale](scale.md): the factory keeps room for ten more Classics and a
+  [scale](scale.md): the factory keeps room for the full press hall and a
   colour store, and the plot keeps a reserve in front for a second hall
   or a PV field.
 - **Factory, production floor only**: 128 × 25 m at floor level +1.2 m,
@@ -179,9 +180,14 @@ and every equipment envelope is an estimate.
     that special designs need, about 100 positions on four levels
     (estimate), with weighing and mixing and a vacuum conveying station
     ([pressing line](equipment/pressing-line.md)).
-  - **Press hall** (~870 m²): two Duplex systems, each two HRP 12 presses
+  - **Press hall** (~870 m²), laid out 60/40 by floor for Duplex systems
-    with an EX 50 and an EX 35, the Classic, and ten more Classic
+    because the plant focuses on special pressings (October 2026,
-    positions in two rows. Each Duplex is one operator's cell of about
+    [pressing line](equipment/pressing-line.md)): four Duplex bays, each
+    for two HRP 12 presses with an EX 50 and an EX 35, along the visitor
+    corridor, and six Classic positions in the second row; the launch
+    plant fills one of each. The FreeCAD model still draws the earlier
+    layout (two Duplex systems, the Classic and ten more Classic
+    positions). Each Duplex is one operator's cell of about
     5 × 3 m at Newbilt's machine sizes: presses either side turned
     towards the operator, the extruders behind him, one trimmer in front
     ([pressing line](equipment/pressing-line.md)).